18SP622 Series 50 Gillig Low Floor Diesel Particulate Filter Installation

Transcription

1 18SP622 Series 50 Gillig Low Floor Diesel Particulate Filter Installation DESCRIPTION A replacement diesel particulate filter assembly has been released for use in Gillig Low Floor buses with Series 50 diesel engines built after serial number 04R The appropriate part numbers to mate with the OEM-installed exhaust tubing are listed in Table 1 below. A partial list of available replacement parts is listed in Table 2. PARTS LIST See Table 1 for the Gillig Low Floor diesel particulate filter parts: Part No. Qty. Description Diesel Particulate Filter Assembly Diesel Particulate Filter Installation Kit 18SP622 1 Installation Instructions Table 1 Components of S50 Gillig Phantom Diesel Particulate Filter Installation Part No. Qty. Description * V-Band Clamp * Gasket * V-Band Clamp and gasket part numbers are provided as a reference for ordering replacement parts, if required, in the event either is damaged during removal or installation. Table 2 Replacement Service Parts for S50 Gillig Phantom Diesel Particulate Filter REMOVAL OF DIESEL PARTICULATE FILTER Perform the following steps for removal of current components: PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves or allow engine to cool before removing any component. 18SP622 Page 1 of 9

2 PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. The diesel particulate filter weighs approximately 36 Kg (80 lbs). 1. Gain access to the muffler / filter compartment. 2. Disconnect the exhaust temperature sensor probe lead, loosen the sensor retaining nut and remove the sensor. Retain the sensor for reuse. 3. Remove the upper U-clamp and mounting bracket securing the top of the outlet section of the filter to the chassis. 4. Remove the exhaust clamp and remove the tail pipe section. 5. Loosen the large V-band clamps that secure the center section of the old filter to the inlet and outlet sections. 6. Remove the center and outlet sections individually. 7. Loosen and remove the exhaust clamp securing the exhaust pipe to the filter inlet; separate the pipe from the muffler. 8. Remove the bolts, washers, and nuts securing the inlet section / bracket assembly to the chassis. Remove the inlet section from the chassis. 9. Leave the original rubber mounts in place. 10. Remove the exhaust piping back to the turbo outlet elbow. 18SP622 Page 2 of 9

3 Installation of Diesel Particulate Filter Perform the following steps for installation of new components; Refer to Figure Clamp, Torctite 5 in. 7. Tadpole Seal 2. Top Bracket Weldment 8. Spacer 3. Bushing 9. Gasket, 1.5 in. I.D. x 3.75 in. O.D. 4. Gasket Receiver Ring 10. Hex Head Cap Screw 5. Lower Band Clamp 11. Spacer Gasket Retainer 6. Hanger Bracket Figure 1 S50 Gillig Low Floor DPF Installation 1. Place gasket receiver ring flat onto compartment floor. Place top bracket weldment over ring so that ring protrudes through the bracket. Position the bracket to match the removed bracket section. Insert four of the ½ in. x 3.75 in. mounting bolts through mounting plate and rubber mounts. Attach washers and nuts to these bolts and hand-tighten. See Figure 2. These mounting bolts act as guides and are used to further position and secure the top bracket in its proper place. 18SP622 Page 3 of 9

4 1. Gasket Receiver Ring 2. Top Bracket Weldment Figure 2 Installing Gasket Receiver Ring and Top Bracket 2. Using the gasket receiver ring as a template, scribe / mark the sheet metal along the inside edge of the ring. Center punch two holes from the bracket to the sheet metal floor. Remove the bolts, bracket, bushings and ring. Holes are near opening in the bracket and are the only holes that do not go through the muffler compartment floor. 3. Cut out the complete circle along the marks made in Step 2. See Figure in. Diameter Hole Figure 3 Cutting 12 in. Hole in Bracket 4. Place and align the gasket receiver ring to the 12 in. cut-out hole. Mark the ring mounting holes and drill out with a ¼ in. drill bit. 5. Locate the center punch marks in the floor and drill two 1.75 in. holes. 6. Using two spacer gasket retainers as templates, place them over the 1.75 in. holes. Transfer the three mounting holes in each plate to the sheet metal floor. Then using a ¼ in. drill bit, 18SP622 Page 4 of 9

5 drill out the holes for each plate. Corresponding holes will need to be made in the gaskets as well. See Figure Spacer Gasket Retainer Figure 4 Installing Spacer Gasket Retainers 7. Attach the two gaskets and two spacer gasket retainers from the engine side of muffler compartment floor using six #10 x 24 x ¾ in. hex head cap screws, six washers, and six lock nuts. Torque to 5-7 N m (4-5 lb ft). See Figure 5. Insert the screws facing down, through the floor. 1. Gasket Receiver Ring 3. Spacer Gasket Retainer 2. Gasket, 1.5 in. I.D. x 3.75 in. O.D. Figure 5 Installing Gasket Receiver Ring and Spacer Gasket Retainer 8. Install gasket receiver ring to the muffler compartment floor using eight #10 x 24 x ¾ in. Hex head screws, eight washers and eight lock nuts. Torque to 5-7 N m (4-5 lb ft). 9. Insert new rubber bushings into the original four holes where the old rubber bushings were removed. 18SP622 Page 5 of 9

6 10. Set top bracket weldment onto the bushings. Install four ½ in. -13 x 3.5 in. bolts through the outermost holes in the top bracket. See Figure Gasket Receiver Ring 2. Top Bracket Weldment Figure 6 Installing Top Bracket Weldment 11. Assemble loosely the hanger brackets to the lower band clamp using eight 3/8 in. -16 x 1.5 in. bolts, sixteen 3/8 in. x 1.00 in. x.019 in. heavy flat washers, eight 3/8 in. lock washers, and eight 3/8 in Hex nuts. Brackets should face away from the center of the band clamp. 12. Working from the engine compartment, install the assembly to the bottom of the muffler compartment floor. On four bolts, install the lower half of the rubber bushings, ½ in. fender washer, and then the hanging bracket followed by a ½ in. flat washer, ½ in. lock washer, and a ½ in. hex nut. See Figure Hanger Bracket 4. Gasket Receiver Ring 2. Bushing 5. Lower Band Clamp 3. Top Bracket Weldment Figure 7 Installing Assembly to Muffler Compartment Floor 13. Install the two spacers into the two 1.75 in. cut-out holes. Install the steel spacers and the hanger bracket using the remaining ½ in. bolts, ½ in. flat washers, ½ in. lock washers, and ½ in. hex nuts. See Figure 8. 18SP622 Page 6 of 9

7 1. Hanger Bracket 4. Spacer Gasket Retainer 2. Lower Band Clamp 5. Spacer 3. Gasket, 1.5 in. I.D. x 3.75 in. O.D. Figure 8 Installing Steel Spacer and Hanger Bracket 14. Loosen the V-band clamps and separate the four sections of the filter. NOTICE: Be careful to avoid damage to the gaskets between each of the filters. 15. Install the lower section down through the bracket and snug up to the mounting clamp using two 5/16 in. -18 x 1.75 in. bolts, four 5/16 in. flat washers, and two 5/16 in. hex nuts. The lower section V-band clamp will be almost touching the bottom mounting clamp. Do not tighten fasteners at this time. See Figure Hanger Bracket 2. Lower Band Clamp Figure 9 Installing Lower Section of Filter 16. Attach the exhaust from the turbocharger to the inlet section using the flex and elbow pieces supplied in the kit. 18SP622 Page 7 of 9

8 17. Install the gasket and clamp on the inlet section upper surface. Install the catalyst section with the part number tag oriented toward the side access door. Secure clamp but leave loose. 18. Feed in the tadpole seal between the catalyst section housing and top bracket. The seal will also need to be fed in between the gasket receiver ring and catalyst section housing. Leave enough of the seal protruding above the top mounting bracket. Use the gasket retainer band and the flat band clamp to clamp the seal to the catalyst housing, using a 3/8 in x 2.5 in. bolt, two 3/8 in. flat washers, a 3/8 in. lock washer, and a 3/8 in. hex nut. See Figure Top Bracket Weldment 3. Gasket Receiver Ring 2. Tadpole Seal Figure 10 Installing Lower Section of Filter 19. Install the gasket and clamp on the upper portion of the catalyst section. Install the filter center section with the part number tag oriented toward the side access door. Secure clamp but leave loose. 20. Install the gasket and clamp on the top of the filter section. Install the outlet section with the part number tag oriented toward the side access door or so as to position the outlet pipe below the hole in the body for the tail pipe. Secure clamp but leave loose. 21. Install the tail pipe with the outlet facing the rear of the vehicle. Secure tail pipe with the Torctite 5 in. band clamp. Install the U-clamp to the existing mounting bracket securing the top of the filter and the outlet tail pipe to the chassis. It may be necessary to modify the bracket. Do not tighten hardware at this time. 22. Install the temperature probe into the M14 x 1.5 in. threaded boss on the side of the outlet can. Tighten the nut using hand tools only. Be sure the sensor wires are secured to avoid contact with the filter body and are not under tension. 23. Tighten the three large clamps securing the filter sections to 16 N m (12 lb ft). 18SP622 Page 8 of 9

9 NOTICE: Do not use an impact wrench to tighten the clamps; this may cause galling of the threads. Check to be sure there is adequate clearance between the filter body and the chassis and adjust if necessary, to allow air circulation. 24. Tighten the mounting hardware to secure the filter in the chassis. The 5/16 in. bolts torque to N m (13-17 lb ft). The 3/8 in. bolts torque to N m (30-35 lb ft). The ½ in. bolts torque to N m (71-75 lb ft). The exhaust pipe band clamps are torqued to 20 N m (15 lb ft). 25. Check for exhaust leaks. 26. Reinstall any access panels. Be sure the exhaust pipe does not contact the upper hood to avoid heat transfer and damage to the fiberglass rear cap on the bus. Copyright 2005 Detroit Diesel Corporation. Detroit Diesel, DDC, and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. All other trademarks are the property of their respective owners. 18SP As technical advances continue, specifications will change. All rights reserved. Printed in U.S.A. 18SP622 Page 9 of 9